RS-232 to Current Loop Converters

CL1060/1090xxx 703 5856 RS-232 to Current Loop Converters DB25F to DB25M Product Code CL1060A-M DB25M to DB25F Product Code CL1060A-F DB25M to Terminal Block Product Code CL1090A-M DB25F to Terminal Block Product Code CL1090A-F Current Loop data communication is unusual in that there is no universally recognized standard for its physical or electrical characteristics. It is up to the installer to familiarize him/herself with the individual system with which they are involved. Luckily, since current loop depends upon the simple presence or absence of current, this is not too difficult. This booklet is to introduce the user to the physical aspects of 20mA current loop communications and assist in linking current loop data systems to serial data systems. In 1963 the Model 33 teletype was introduced and the 20mA current loop interface became a defacto standard. At that time current loop interfaces became popular because they offered the most cost effective approach to long distance, noise immune transmission. The 20mA current loop is suitable for distances to 2,000 feet (600 meters) at data rates up to 19.2kbps. It can be used at longer distances when data rates are as low as 300 baud. Black Box Corporation 1000 Park Drive, Lawrence PA, 15055-1018 Technical Support and Ordering: 724-746-5500 Fax: 724-746-0746 To contact us about Black Box products or services: info@blackbox.com RS-232 to Current Loop Converters 1 2 RS-232 to Current Loop Converters

1.0 The Basics of Current Loop 1.1 Full-duplex 20 ma Circuit Figure 1 is a full-duplex 20 ma current loop circuit. Simultaneous two-way communications is possible with this circuit. Two 20 ma current generators are necessary with this circuit. It is possible to have one of the two current generators in one current loop interface and the other current generator in the other interface. For example, the original IBM PC serial adapter card had a current loop interface that contained only one current generator. When you made a correct connection to this current loop interface, the second current loop device would need to provide one current loop generator. 1.2 The Simplex 20 ma Circuit Figure 2 is a diagram of a simplex 20 ma current loop circuit. The fundamental elements of a 20 ma current loop are a current source, a current switch, and a current detector. The transmitter is the current switch and the receiver is the current detector. The interface that contains the current source is called the active unit and all other units are referred to as passive units. Figure 3 is a diagram of the levels in an RS-232 interface and how they relate to the presence and absence of current in a 20 ma current loop circuit. In a 20 ma loop the current flows when the loop is idle (no data being transmitted). In a simplex type circuit a number of transmitters and receivers are put in series in a current loop. As long as only one transmitter sends data, all receivers receive the data. Receiver (Only one device can transmit at a time) Transmitter Receiver Receiver 20 ma current loop generator Receiver Transmitter 20 ma current loop generator Active side Passive side Transmitter (Current is ON when data is not transmitted) 20 ma current loop generator Transmitter (Current is ON when data is not transmitted) passive side Figure 1. Full duplex 20 ma circuit active side Figure 2. Simplex 20 ma Circuit RS-232 to Current Loop Converters 3 4 RS-232 to Current Loop Converters

+15 volts +3 volts 0 volts - 3 volts -15 volts SPACE Transistion region MARK RS-232 Circuit Flow of 20-mA current is interrupted 20-mA current flows in circuit 20-mA circuit Figure 3. Comparison of signal levels in an RS-232 Circuit and a 20-mA Current loop Circuit I loop = (Vs - V transmitter -V receiver)/rs for typical optocouplers V transmitter (U1) =.2 v when turned ON V receiver (U2) = 1.8 v when input LED is conducting If Vs = 12 volts & Rs = ohms then I loop = (12v -.2v - 1.8v)/ ohms 1.3 Problems with 20 ma Current Loop The main problem with 20 ma current loop is that there is no mechanical or electrical standard defined for this interface. This makes every interface somewhat unique and the user must know some of the technical details about the circuits used in the interface. I loop = 10v/ ohms = 21.3 ma If we changed Vs = 60 v and left Rs = then I loop = (60v -.2v -1.8v)/ ohms = 123 ma If we changed Vs = 5 v and left RS = ohms then Data In U1 I loop = (5v -.2v -1.8v)/ ohms = 6.4 ma Vs Rs Current switch (Transmitter) Current generator U2 Current detector (Receiver) Data Out The point of showing these different calculations is to demonstrate that the loop currents circuit can vary by considerable amounts, if Vs is varied. Likewise, if Rs was changed the loop currents could also vary considerably. The only way to determine that currents are near 20 ma is to examine the circuit in detail. 1.4 Current Regulation in Current Loops Figure 4. Simplified one direction current loop Figure 4 is a simplified one-way current loop implemented with two optocouplers, a voltage source, and a resistor. Optocoupler U1 is the transmitter and optocoupler U2 is the receiver. The value of the loop current in this circuit is: Several methods can be used to control the amount of current in a current loop circuit. This section will illustrate several common methods of regulating the current in a current loop. RS-232 to Current Loop Converters 5 6 RS-232 to Current Loop Converters

1.4.1 Constant Current Generator Current Source Figure 5 is a circuit that uses a linear voltage regulator integrated circuit to serve as a constant current source. Almost any fixed or adjustable voltage regulator can be used. The example shown in Figure 6 uses an LM317 adjustable regulator because is provides a low amount of voltage drop (3 volts) across the current regulator circuit. For example, if Vs was 12 volts in this circuit, then the maximum voltage that the constant current regulator could drive would be 9 volts. The 62 ohm, Rg resistor sets the regulator current because there is an internal voltage reference in the LM317 between VO and the ADJ pins of 1.25 volts. VI LM317 Adj VO Rg 62 1.4.2 Transmitter Current Limiter Some current loop interfaces incorporate current limiting into the transmitter (current switch) itself. Figure 6 is an example of a circuit that has built-in current limiting so that the loop current cannot exceed 20 ma. In this circuit Rg provides a source of bias current for Q2 so that if the loop current tries to exceed 20 ma Q2 will shunt Q1 base bias current so that Q1 will not conduct more than 20 ma. Q1 U1 Rg I emitter (max.) =.7 Rg Vs I loop = 1.25/Rg = 1.25/62 = 20 ma I loop Maximum output voltage equal to (Vs - 3v) Figure 7. Current Limiter built into Receiver 1.4.3 Receiver Current Limiter Figure 5. Constant Current Generator for a 20 ma Current Loop In a current loop, the sum of all the voltage drops across all the devices must be less than the voltage source, Vs driving the loop. Each device in the current loop whether it is a transmitter (current switch) or receiver (current detector) has some voltage drop across it. For instance, a typical transistor switch can have typically 0.2 volts drop across it. However, the voltage drop across the transmitters can be as much 2.3 volts when the switch is turned ON. The reason for this is that the transmitter switch must provide for the reverse bias of the internal photo detector diode inside the optocoupler. An optocoupler used as a current detector will have from 1.2 to 2.0 volts drop across it. The circuit shown in Figure 7 is used not to regulate the loop current, but to regulate the maximum emitter current in the optocoupler U1. This is done because some optocouplers require less than 20 ma to operate at maximum speed. Transistor Q1 is used to shunt some of the loop current around the emitter of optocoupler U1. RS-232 to Current Loop Converters 7 8 RS-232 to Current Loop Converters

2.0 Current Loop Interface Connections To connect our converter to an existing current loop port, you must first determine if the port is active or passive. What this means is: does the port have an internal power supply that provides the current (active) for the transmitter, the receiver, or both (transmitter and receiver). The simplest way to determine this is to break the loop (disconnect it) and see if there is any DC voltage across the output or input pairs. If you have access to the instruction manual for the unit you can also look in there for the information. Current loop interfaces normally consist of four wires. They are usually labeled,,, and. and are the transmit plus and transmit minus lines and data is output from that device on those lines. The and lines are the receive plus and receive minus lines and data is input into that device on these lines. Interconnection of the two current loop devices is different depending on whether your unit is active or passive. 2.1 Connection to an Active Current Loop Port Connection to an active current loop port is very simple. Your units and lines go to our units and lines. And your units and lines go to our units and lines. See the following drawing. RS-232 to Current Loop Converter Note: The & indentification doesn't imply a direct connection across the receiver. Note: The & indentification doesn't imply a direct connection across the transmitter. Figure 8. Connection to an Active Current Loop Vs Vs Active Current Loop Port 2.2 Connection to a Passive Current Loop Port Connection to a passive current loop port is a little harder. You must use a 12 VDC power supply with the ohm resistors inside of our converter to "create" a 20 ma current source. See the following drawing. RS232 TO CURRENT LOOP CONVERTER 14 19 6 9 21 22 25 23 +12VDC PASSIVE CURRENT LOOP CONVERTER YOUR EQUIPMENT Figure 9. Connection to a Passive Current Loop (DB-25 pinout numbers shown apply to Models 1060A-F and 1060A-M only.) 2.3 Interconnection of Two Current Loop Converters Interconnection of two current loop converters also requires the use of a 12 VDC power supply since they are both passive port. See the following drawing. 14 19 6 9 21 22 25 23 +12VDC 14 19 21 22 25 23 Figure 10. Interconnection of Two Curent Loop Converters (DB-25 pinout numbers shown apply to Models 1060A-F and 1060A-M only.) 6 9 RS-232 to Current Loop Converters 9 10 RS-232 to Current Loop Converters

3.0 What Isn t Digital Current Loop 3.1 4 to 20 ma Analog Current Loop The diagram shown in Figure 11 is an analog 4 to 20 ma current loop. This circuit is mentioned here because it is sometimes confused with 20 ma digital current loop. The purpose of 4 to 20 ma analog current loop is to transmit the signal from an analog sensor over some distance in the form of current signal. Only two wires are required to send the analog signal and also supply power to the sensor. A loop supply voltage (24 volts in Figure 11) is used to power the remote sensor. The remote sensor regulates the loop current such that the loop current represents the value of the parameter being measured by the sensor. A series resistor RL at loop power supply converts this current to a voltage that can be used by the electronics to record or distribute the parameter being measured. Control system +0.5mA 0-0.5mA 1,200 Hz 2,200 Hz "1" "0" Cable to Sensor 4 to 20 ma analog plus digital communications Analog Signal Remote Smart sensor with HART communications protocol sensor Frequency Shift Keying (FSK) Modulation used to add digital information to the analog 4 to 20 ma signal Figure 12. 4 to 20 ma analog current loop with digital communications using HART protocol V+ never drops below +12 v Loop Supply 24 v Cable to Sensor V+ Remote sensor electronics Sensor Output Signal R L may draw up to 4 ma Com sensor Figure 11. 4 to 20 ma analog current loop 3.2 HART(R) 4 to 20 ma Current Loops Figure 12 is another example of a type of 4 to 20 ma combined analog & digital current loop. This current loop uses HART(R) Communications protocol. The HART(R) (Highway Addressable Remote Transducer) protocol is used for SMART remote transducers that are compatible with 4 to 20 ma analog current loops but also have digital communications on the same two wires. This is accomplished by superimposing a two-tone Frequency Shift Keyed (FSK) digital current signal on the 4 to 20 ma analog signal. RS-232 to Current Loop Converters 11 12 RS-232 to Current Loop Converters

Converter Schematics CL1090A-M CL1060A-F CL1090A-F CL1060A-M RS-232 to Current Loop Converters 13 14 RS-232 to Current Loop Converters

FEDERAL COMMUNICATIONS COMMISSION RADIO FREQUENCY INTERFACE STATEMENT Class A Equipment This equipment has been tested and found to comply with the limits for Class A digital device, pursuant to Part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment. This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in accordance with the instructions, may cause harmful interference to radio communications. Operation of this equipment in a residential area is likely to cause harmful interference, in which case the user will be required to correct the interference at personal expense. Black Box Corporation - 1000 Park Drive - Lawrence PA, 15055-1018 Technical Support and Ordering: 724-746-5500 Fax: 724-746-0746 To contact us about Black Box products or services: info@blackbox.com RS-232 to Current Loop Converters 15 16 RS-232 to Current Loop Converters